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Replacing the alternator on a Zetec.
#3
I pulled mine out through the top. I followed the instructions in the Haynes manual.

1. move coolant overflow and PS reservoir out of the way.
2. bend PS reservoir bracket 'tab' down, out of the way.
3. have a beer.
4. remove serpentine belt.
5. remove or loosen bolts. You won't be able to remove one bold until the whole alternator is moved.
6. undo electrical connections on alternator (old grounding post may snap off).
7. undo bolts holding stuff to firewall, intake, head, etc.
8. have another beer.
9. turn the alternator pulley side up in the little bit of cavity you've made.
10. swear at Ford for such a stupid design.
11. try to pull the alternator out, while wiggling it, turning it, swearing, throwing tools, etc... It will eventually come out.
12. have another beer.
13. maneuver new alternator into place, reverse of removal. Swearing, throwing tools, turning and wiggling all involved. More beer too.

It's a frigging picnic, and a good time will be had by all. As long as there is enough beer, bandaids, and tools to throw. Smile It took me a total of 4 hours. Once I got it done, I realized that if I could rock the engine forward about 1 inch, it would be alot easier. Maybe undo the rear motor mount (dog bone), and jack up on it, to 'roll' the engine forward.
Ryan and the Silver Sedan
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2008 Mazda5 GS/Copper Red Mica/2.3 MZR 5AT/22% Tint
[Image: 49951.png]
2011 Ford F150 FX4 Supercrew/Race Red/3.5 TT EcoBoost
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Messages In This Thread
RE: Replacing the alternator on a Zetec. - reldridge - 04-01-2011, 01:39 PM
RE: Replacing the alternator on a Zetec. - 02ztsian - 04-02-2011, 11:02 PM

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